SELF-STANDING FOLDABLE CONTAINER APPARATUSES AND METHODS OF USING THE SAME
A self-standing foldable composite container apparatus comprises, preferably, a vertical cuboid body, namely having the shape of a square prism, rectangular prism, or cube. The container apparatus may be made from one or a plurality of layers of woven polymeric material, further having plastic inserts therein to maintain the shape thereof, reinforce the sides thereof, and further allow the containers to self-stand. The top and bottom of the container apparatus may comprise covers that may be relatively flat, the top cover having a flap openable by one or more zippers and having at least a pair of lifting loops for lifting the same with a forklift or other like lifting mechanism. Methods of using the same are further provided.
The present invention claims priority to U.S. Prov. Pat. App. Ser. No. 63/410,415, titled “Self-Standing Foldable Composite Intermediate Bulk Container Apparatuses and Methods of Using the Same,” filed Nov. 27, 2022, which is incorporated herein by reference in its entirety.
TECHNICAL FIELDThe present invention relates to self-standing foldable composite container apparatuses. Specifically, the self-standing composite container apparatuses comprises, preferably, a vertical cuboid body, namely roughly having the shape of a square prism, a rectangular prism, or cube. The container apparatuses are made from one or a plurality of layers of woven polymeric material, further having plastic inserts therein to maintain the shape thereof, reinforce the sides thereof, and allow the containers to self-stand. The top and bottom of the container apparatus comprise covers that may be relatively flat, the top cover having a flap openable by one or more zippers and having at least a pair of lifting loops for lifting the same with a forklift or other like lifting mechanism. Methods of using the same are further provided.
BACKGROUNDMaterials may typically be shipped by drums that are disposed on pallets which are then loaded into shipping containers, trucks, railcars, or other like shipping means. Specifically, hazardous materials, namely materials falling into Packing Groups I, II, and III, are typically stored and shipped in drums namely due to the strength of the drums, which typically have hard sides, a sealed bottom, and a top that is easily sealable after waste is place therein, pursuant to U.S. Department of Transportation regulations, specifically regulations specified in 49 CFR Parts 106, 107, and 171-180.
Once a drum is used to store and ship material and then emptied, the drum is typically cleaned and reused. However, oftentimes the drums must first be shipped back to the source facility for further cleaning and processing for reuse. Therefore, the drums are often shipped back to the source facility empty. Because the drums are solid in shape, they cannot be reduced in size in any capacity. As such, the drums are typically shipped back with nothing but air inside. And the amount of space required to ship the drums can be large and expensive.
Drums also have shapes that are difficult to transport, creating wasted space and other inefficiencies. Typically, drums typically have a cylindrical or tubular shape. Traditional drums in the form of barrels may have bulges across the middle thereof making them difficult to store and ship together. Often, drums or barrels are placed on a pallet, tied down to each other and/or the pallet, and shipped to and from customers in that manner.
Intermediate bulk containers (IBCs) are also used to ship materials but are typically not used for storing and transporting hazardous materials. An IBC may be either rigid (typically made of hard plastic material and surrounded by a cage for reinforcement) or may be flexible. IBCs may be made from many materials, such as fiberboard, wood, aluminum, and folding plastic. Typically foldable flexible IBCs have sides that fold inward when the unit is empty allowing the IBC to collapse into a much smaller package for return shipment or storage.
Rigid IBCs, on the one hand, of course, suffer the same issues as drums and barrels, as noted above. Rigid IBCs are not, by their nature, flexible, and typically are shipped in the same manner as drums and barrels. Because they are not typically flexible or foldable, they take up the same amount of space no matter whether they are empty or full.
Flexible IBCs, on the other hand, may not have sufficient strength and safety properties to handle storing and shipping material therein, especially hazardous materials. With respect to hazardous materials, flexible IBCs are generally not approved for use therewith. Often, flexible IBCs are made from heavy plastic that are wrapped into a bag configuration. Such a configuration introduces weaknesses into the apparatus causing the same to burst if filled with much material. Flexible IBCs may simply lack the strength due to their design abd materials made therefrom to prevent damage thereto when filled with relatively heavy material or with objects that may pierce the material from which the flexible IBC is made.
In addition, flexible IBCs also may be difficult to fold or otherwise change into smaller forms while also allowing them to be easily re-formed into shapes that are easy to fill. In addition, flexible IBCs are typically not self-standing and must often be held open and aloft when adding material or objects thereto.
A need, therefore, exists for improved container apparatuses. Specifically, a need exists for improved container apparatuses that are used to hold material and objects that are typically shipped using drums and/or barrels. More specifically, a need exists for improved container apparatuses that have strength and resiliency properties that are similar to typical drums and/or barrels that are used to ship material and objects.
Moreover, a need exists for improved container apparatuses that are flexible and may be reduced in size when empty. Specifically, a need exists for improved container apparatuses that are easily foldable and stackable. More specifically, a need exists for improved container apparatuses that are easily openable when folded to access the interior thereof for cleaning and/or loading with additional material or objects.
In addition, a need exists for improved container apparatuses that are free-standing. Specifically, a need exists for improved container apparatuses that may be maintained in an upright and open configuration making it easy to load with material or objects. Moreover, a need exists for improved container apparatuses that may be easily lifted and moved.
SUMMARY OF THE INVENTIONThe present invention relates to self-standing foldable composite container apparatuses. Specifically, the self-standing composite container apparatuses comprises, preferably, a vertical cuboid body, namely roughly having the shape of a square prism, a rectangular prism, or cube. The container apparatuses are made from one or a plurality of layers of woven polymeric material, further having plastic inserts therein to maintain the shape thereof, reinforce the sides thereof, and allow the containers to self-stand. The top and bottom of the container apparatus comprise covers that may be relatively flat, the top cover having a flap openable by one or more zippers and having at least a pair of lifting loops for lifting the same with a forklift or other like lifting mechanism. Methods of using the same are further provided.
To this end, in an embodiment of the present invention, a container apparatus is provided. The container apparatus comprises a body having a tubular configuration formed from a plurality of layers and having a plurality of side walls without any vertical seams, the body having a plurality of corners, each corner forming a vertex of the plurality of side walls thereby forming a cuboid shape, the body further having a top cover and a bottom cover thereby forming an interior space within the body; a flap disposed in the top cover configured to open forming an opening in the top cover to access the interior space; an inner liner bag disposed within the interior space; and first and second flat panel inserts within first and second pockets, respectively, within each of the plurality of side walls forming a fold line between the first and second flat panel inserts within each of the side walls.
In an embodiment, the layers are made from woven polypropylene.
In an embodiment, each of the corners is rounded.
In an embodiment, the flap comprises a zipper around a periphery thereof for closing to and opening from the top cover.
In an embodiment, the inner liner bag is adhered to an inner wall of the body.
In an embodiment, the container apparatus comprises a tab extending from an inner wall of the body, wherein the inner liner is affixed to the tab.
In an embodiment, the container apparatus further comprises at least one layer of woven polypropylene disposed over the inner bag liner, thereby sandwiching the inner bag liner between at least one side wall of the body and the at least one layer of woven polypropylene.
In an embodiment, the container further comprises a first strap connected to a first corner of the body and a second corner of the body forming a first loop.
In an embodiment, the first corner and the second corner are adjacent to each other.
In an embodiment, the container apparatus further comprises a second strap connected to a third corner of the body and a fourth corner of the body forming a second loop.
In an embodiment, the first and second corners are adjacent to each other and the third and fourth corners are adjacent to each other.
In an embodiment, the inner bag liner comprises a neck that is configured to extend through opening in the top cover.
In an alternate embodiment of the present invention, a method of using a container apparatus is provided. The method comprising the steps of: providing a container apparatus comprising a body having a tubular configuration formed from a plurality of layers and having a plurality of side walls without any vertical seams, the body having a plurality of corners, each corner forming a vertex of the plurality of side walls thereby forming a cuboid shape, the body further having a top cover and a bottom cover thereby forming an interior space within the body, and first and second flat panel inserts within first and second pockets, respectively, within each of the plurality of side walls forming a fold line between the first and second flat panel inserts within each of the side walls, wherein the container apparatus is in a folded state; and unfolding a first sidewall via a first fold line between the first and second panel inserts within the first sidewall; unfolding a second sidewall via a second fold line between the first and second panel inserts within the second sidewall; and standing the body upright with each of the sidewalls in an unfolded configuration.
In an embodiment, the method further comprises the steps of: providing a flap disposed in the top cover configured to open forming an opening in the top cover to access the interior space; opening the flap and forming the opening in the top cover; and accessing the interior space of the body.
In an embodiment, the flap comprises a zipper around a periphery thereof and wherein opening the flap is caused by unzipping the zipper around the periphery of the flap.
In an embodiment, the method further comprises the steps of: providing an inner liner bag within the body having an opening accessible through the opening in the top cover; and opening the inner liner bag and accessing an interior of the inner liner bag.
In an embodiment, the inner liner bag comprises a neck that is configured to extend through the opening in the top cover, and the method further comprises the step of: extending the neck of the inner liner bag through the opening prior to opening the inner liner bag and accessing the interior of the inner liner bag.
In yet another alternate embodiment of the present invention, a method of using a container apparatus is provided. The method comprises the steps of: providing a container apparatus comprising a body having a tubular configuration formed from a plurality of layers and having a plurality of side walls without any vertical seams, the body having a plurality of corners, each corner forming a vertex of the plurality of side walls thereby forming a cuboid shape, the body further having a top cover and a bottom cover thereby forming an interior space within the body, and first and second flat panel inserts within first and second pockets, respectively, within each of the plurality of side walls forming a fold line between the first and second flat panel inserts within each of the side walls; and folding a first sidewall at the fold line between the first and second flat panel inserts within the first sidewall inwardly toward the interior space.
In an embodiment, the method further comprising the steps of: folding a second sidewall at the fold line between the first and second flat panel inserts within the second sidewall inwardly toward the interior space; and flattening the body of the container apparatus.
In an embodiment, the method further comprises the steps of: providing a flap disposed in the top cover configured to open forming an opening in the top cover to access the interior space; and closing the flap disposed in the top cover thereby closing the opening in the top cover prior to folding the first sidewall and the second sidewall.
It is, therefore, an advantage and objective of the present invention to provide improved container apparatuses.
Specifically, it is an advantage and objective of the present invention to provide improved container apparatuses that are used to hold material and objects that are typically shipped using drums and/or barrels.
More specifically, it is an advantage and objective of the present invention to provide improved container apparatuses that have strength and resiliency properties that are similar to typical drums and/or barrels that are used to ship material and objects.
Moreover, it is an advantage and objective of the present invention to provide improved container apparatuses that are flexible and may be reduced in size when empty.
Specifically, it is an advantage and objective of the present invention to provide improved container apparatuses that are easily foldable and stackable.
More specifically, it is an advantage and objective of the present invention to provide improved container apparatuses that are easily openable when folded to access the interior thereof for cleaning and/or loading with additional material or objects.
In addition, it is an advantage and objective of the present invention to provide improved container apparatuses that are free-standing.
Specifically, it is an advantage and objective of the present invention to provide improved container apparatuses that may be maintained in an upright and open configuration making it easy to load with material or objects.
Moreover, it is an advantage and objective of the present invention to provide improved container apparatuses that may be easily lifted and moved.
Additional features and advantages of the present invention are described in, and will be apparent from, the detailed description of the presently preferred embodiments and from the drawings.
The drawing figures depict one or more implementations in accord with the present concepts, by way of example only, not by way of limitations. In the figures, like reference numerals refer to the same or similar elements.
The present invention relates to self-standing foldable composite container apparatuses. Specifically, the self-standing composite container apparatuses comprises, preferably, a vertical cuboid body, namely roughly having the shape of a square prism, a rectangular prism, or cube. The container apparatuses are made from one or a plurality of layers of woven polymeric material, further having plastic inserts therein to maintain the shape thereof, reinforce the sides thereof, and allow the containers to self-stand. The top and bottom of the container apparatus comprise covers that may be relatively flat, the top cover having a flap openable by one or more zippers and having at least a pair of lifting loops for lifting the same with a forklift or other like lifting mechanism. Methods of using the same are further provided.
Referring now to
Preferably, the corners 14 may be rounded and formed by several layers folded back and forth on itself and stitched together, providing a relatively high amount of strength in the corners. Preferably, the body 12 is formed from a plurality of flexible woven polypropylene layers that are adhered or otherwise fused together to form a strong and resilient outer shell.
As illustrated in
The container apparatus 10 may further have a top cover 18 and a bottom cover 20, generally formed from a square of flexible, woven polypropylene material (in a single or plurality of layers) or other cross-sectional shape of the container apparatus 10, that may be stitched around the perimeter of the top of the body 12 and the bottom thereof, respectively, thereby enclosing a space 22 disposed within the body 12.
The top cover 18 may have a zippered U-shaped opening flap 24 therein, having a hinged side 26 and a zippered portion 28 for closing over an opening 29. The zippered opening flap 24 may have a pair of zippers 30a, 30b running over the zippered portion 28 for ease of opening and/or closing the same, as further shown in
The top cover 18 and the bottom cover 20 may be made from one or more layers of, preferably, woven polypropylene, and the zippered portion 28 may be reinforced with additional material and stitching for additional strength and resiliency. Optionally, a rigid and/or foldable insert panel 60 (as illustrated in
Disposed within the space 22 of the body 12 may be a flexible plastic liner bag 32 that may be adhered or otherwise disposed on the bottom 20 and/or sides of the body 12 of the container apparatus 10 and may have an extended neck or duffel portion 33 that may be pulled up and out of the body 12 through the opening 29. As illustrated in
Preferably, the inside of the body 12 may have one or more tabs 35 (as illustrated in
In another embodiment, the liner bag 32 may be hidden within the body 12, wherein another one or more layers of polypropylene (not shown) may be disposed over the liner bag 32 within the body 12. Therefore, the liner bag 32 may be sandwiched between multiple layers of woven polypropylene.
In an alternate embodiment of the present invention, illustrated in
Referring back to
The container apparatus 10 may preferably be used to store and transport material and objects therein and the features described herein allow the storage and transport with no or minimal risk of leakage or spillage of the objects or materials from within. Preferably, the container apparatus 10 may be utilized for hazardous waste storage and transport, such as material falling in to hazard class 3, 4.1, 4.2, 4.3, 5.1, 6.1, 8, or 9, which may fall into Packing Groups I, II, and/or III, in place of drums or barrels, as authorized to be shipped in lap packs in accordance with 49 CFR 173.12(b), for example. Because the container apparatus 10 stands by itself in an upright configuration, it may be easily loaded and may also easily stack onto pallets or the like for transport of the same. The cuboid shape of the container apparatus 10 allows many to be stacked adjacent each other with maximum spatial efficiency.
Transporting empty container apparatuses 10, as described herein, may also be accomplished easily, requiring minimal space. When empty, the container apparatus 10 of the present invention may be folded down to a flat configuration, as illustrated in
Optionally, as detailed above, the bottom 20 of the container apparatus 10 may have an insert 60, as illustrated in
Thus, the container apparatus 10 may be folded and flattened when not in use, allowing the same to be easily stored and transported, such as a to a user for use thereof or from a user back to the manufacturer for cleaning, reuse, or the like. A plurality of folded and flattened container apparatuses may be stacked upon each other to minimize space constraints.
While the present invention details a container apparatus 10 having a rectangular or cuboid prism shape, it should be noted that the container apparatus 10 may be any shape and size and should not be limited as described herein. For example, the container apparatus 10 may have a cube shape, wherein each dimension thereof is roughly the same size. In an exemplary embodiment, the container apparatus 10 of the present invention may have width and length dimensions of about 24″ each and a height dimension of about 34″. Alternatively, the container apparatus 10, having roughly a cube shape thereof, may have width, length, and height dimensions of about 36″ each. Of course, the present invention may be any dimensional length and the present invention should be limited as described herein.
It should be noted that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the present invention and without diminishing its attendant advantages. Further, references throughout the specification to “the invention” are nonlimiting, and it should be noted that claim limitations presented herein are not meant to describe the invention as a whole. Moreover, the invention illustratively disclosed herein suitably may be practiced in the absence of any element which is not specifically disclosed herein.
Claims
1. A container apparatus comprising:
- a body having a tubular configuration formed from a plurality of flexible layers and having a plurality of side walls, the body having a plurality of corners, each corner forming a vertex of the plurality of side walls thereby forming a cuboid shape, the body further having a top cover and a bottom cover thereby forming an interior space within the body;
- a flap disposed in the top cover configured to open forming an opening in the top cover to access the interior space;
- an inner liner bag disposed within the interior space; and
- first and second flat panel inserts within first and second pockets, respectively, within each of the plurality of side walls forming a fold line between the first and second flat panel inserts within each of the side walls.
2. The container apparatus of claim 1 wherein the layers are made from woven polypropylene.
3. The container apparatus of claim 1 wherein each of the corners is rounded.
4. The container apparatus of claim 1 wherein the flap comprises a zipper around a periphery thereof for closing to and opening from the top cover.
5. The container apparatus of claim 1 wherein the inner liner bag is adhered to an inner wall of the body.
6. The container apparatus of claim 1 further comprising:
- a tab extending from an inner wall of the body, wherein the inner liner bag is affixed to the tab.
7. The container apparatus of claim 1 further comprising:
- a spout disposed through the inner liner bag configured to open and allow material to fill the space within the inner liner bag or remove the material from the inner liner bag.
8. The container apparatus of claim 1 further comprising:
- a first strap connected to a first corner of the body and a second corner of the body forming a first loop.
9. The container apparatus of claim 8 wherein the first corner and the second corner are adjacent to each other.
10. The container apparatus of claim 8 further comprising:
- a second strap connected to a third corner of the body and a fourth corner of the body forming a second loop.
11. The container apparatus of claim 10 wherein the first and second corners are adjacent to each other and the third and fourth corners are adjacent to each other.
12. The container apparatus of claim 1 wherein the inner liner bag comprises a neck that is configured to extend through opening in the top cover.
13. A method of using a container apparatus comprising the steps of:
- providing a container apparatus comprising a body having a tubular configuration formed from a plurality of flexible layers and having a plurality of side walls, the body having a plurality of corners, each corner forming a vertex of the plurality of side walls thereby forming a cuboid shape, the body further having a top cover and a bottom cover thereby forming an interior space within the body, and first and second flat panel inserts within first and second pockets, respectively, within each of the plurality of side walls forming a fold line between the first and second flat panel inserts within each of the side walls, wherein the container apparatus is in a folded state;
- unfolding a first sidewall via a first fold line between the first and second panel inserts within the first sidewall;
- unfolding a second sidewall via a second fold line between the first and second panel inserts within the second sidewall; and
- standing the body upright with each of the sidewalls in an unfolded configuration.
14. The method of claim 13 further comprising the steps of:
- providing a flap disposed in the top cover configured to open forming an opening in the top cover to access the interior space;
- opening the flap and forming the opening in the top cover; and
- accessing the interior space of the body.
15. The method of claim 14 wherein the flap comprises a zipper around a periphery thereof and wherein opening the flap is caused by unzipping the zipper around the periphery of the flap.
16. The method of claim 14 further comprising the steps of:
- providing an inner liner bag within the body having an opening accessible through the opening in the top cover; and
- opening the inner liner bag and accessing an interior of the inner liner bag.
17. The method of claim 16 wherein the inner liner bag comprises a neck that is configured to extend through the opening in the top cover, and further comprising the step of:
- extending the neck of the inner liner bag through the opening prior to opening the inner liner bag and accessing the interior of the inner liner bag.
18. A method of using a container apparatus comprising the steps of:
- providing a container apparatus comprising a body having a tubular configuration formed from a plurality of layers and having a plurality of side walls without any vertical seams, the body having a plurality of corners, each corner forming a vertex of the plurality of side walls thereby forming a cuboid shape, the body further having a top cover and a bottom cover thereby forming an interior space within the body, and first and second flat panel inserts within first and second pockets, respectively, within each of the plurality of side walls forming a fold line between the first and second flat panel inserts within each of the side walls; and
- folding a first sidewall at the fold line between the first and second flat panel inserts within the first sidewall inwardly toward the interior space.
19. The method of claim 18 further comprising the steps of:
- folding a second sidewall at the fold line between the first and second flat panel inserts within the second sidewall inwardly toward the interior space; and
- flattening the body of the container apparatus.
20. The method of claim 18 further comprising the steps of:
- providing a third panel insert within the bottom cover of the container apparatus, wherein the third panel insert is foldable.
Type: Application
Filed: Sep 27, 2023
Publication Date: Mar 28, 2024
Inventors: William Duffy Bennett (Chicago, IL), James R. Bennett (Rockford, IL)
Application Number: 18/373,556